15S34 - Fuel Tank And Canister Purge Valve Inspection And Repair

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NHTSA Campaign Number: 15V793
Component(s): FUEL SYSTEM, GASOLINE
Potential Number of Units Affected: 411,205

Manufacturer: Ford Motor Company

SUMMARY:

Ford Motor Company (Ford) is recalling certain model year 2010-2011 Ford Fusion vehicles manufactured July 21, 2008, to March 4, 2011, and 2010-2011 Mercury Milan vehicles manufactured July 23, 2008, to December 10, 2010.

The affected vehicles have fuel vapor canisters whose purge valves may not operate properly resulting in abnormal pressure changes in the fuel tank.

CONSEQUENCE:

The pressure changes may cause the tank to crack and leak fuel.

A fuel leak in the presence of an ignition source increases the risk of a fire.

REMEDY:

Ford will notify owners, and dealers will update the vehicle powertrain control modules and inspect the vehicle for any diagnostic trouble codes (DTCs) for this issue and perform a leak test on the Canister Purge Valve (CPV).

The fuel tank will be inspected for cracks.

The CPV and fuel tank will be replaced as necessary.

These repairs will be performed free of charge.

The recall began on January 15, 2016.

Owners may contact Ford customer service at 1-866-436-7332.

Ford’s number for this recall is 15S34.

NOTES:

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Check if your Vehicle has a Recall

July 5, 2016

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Safety Recall 15S34 – Supplement #3
Certain 2010-2011 Model Year Fusion and Milan Vehicles Equipped with 2.5L or 3.0L Engines
Fuel Tank and Canister Purge Valve Inspection and Repair

REASON FOR THIS SUPPLEMENT

Service action: Limited quantities of fuel tanks are expected to be available the week of July 4, 2016. The SSSC will make outbound phone calls to dealers in order to coordinate shipping the initial fuel tanks for customer vehicles that have been down the longest. After all vehicles with customers in long term rentals have been repaired, fuel tank orders will be fulfilled on a first in, first out basis.
Interim repairs: Claims with labor operation codes 15S34EE, 15S34FF or claims for long term rental, rental tracking allowance, or maintenance and storage using program code 15A05 must be submitted before September 1, 2016 to be eligible for payment.

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
Fusion with 2.5L or 3.0L Engines	2010-2011	Hermosillo	July 21, 2008 through March 4, 2011
Milan with 2.5L or 3.0L Engines	2010-2011	Hermosillo	July 23, 2008 through December 10, 2010

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles, the evaporative emissions Canister Purge Valve (CPV) may develop an internal leak which, under certain circumstances, can allow excessive vacuum to build in the fuel tank. Repeated cycles of this condition may cause a crack in the fuel tank, resulting in a fuel leak or fuel odor. A fuel leak in the presence of an ignition source can lead to a fire.

Additionally, a tank with the subject condition could cause the Malfunction Indicator Light (MIL) to illuminate as a result of an On-Board Diagnostic (OBD) leak check, and may exceed the maximum allowable hydrocarbon evaporative emissions.

SERVICE ACTION

Dealers are directed to complete the following:

Powertrain Control Module (PCM) reprogramming using IDS release 99.05 or later
CPV testing and replacement if needed
If the CPV is leaking, vapor canister inspection and replacement if needed
Fuel tank inspection and replacement if needed

Fuel tanks are expected to be available the week of July 4, 2016. Until fuel tanks become available in sufficient quantities to repair all vehicles, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site to place a part order and request a long term rental vehicle, if needed.

Provide the customer with a “Vehicle Did Not Pass Fuel Tank Inspection – Fuel Tank Not Available” Customer Information Sheet, Attachment V.

NOTE: Any aftermarket replacement fuel tanks that may be available may not meet Ford standards and are not approved for use.

NOTE: The State of California and the Commonwealth of Massachusetts require the completion of emission related recall repairs prior to vehicle registration renewal. For vehicles registered in these states, please provide the owner with a Vehicle Emission Recall Proof of Correction certificate after the repair has been performed if one is requested by the owner. These certificates may be obtained by contacting your regional office.

OWNER NOTIFICATION MAILING SCHEDULE

Owner Letters were mailed the week of January 11, 2016. Owners of vehicles equipped with 2.5L engines and automatic transmissions were advised to schedule service appointments starting February 4, 2016 and later. Owners of all other vehicles were advised to bring their vehicle to dealers for inspection and repair only if their vehicle exhibits symptoms consistent with fuel tank leaks.

A follow-up notification will be sent to owners of 2.5L manual transmission vehicles and 3.0L vehicles the week of April 11, 2016 informing them that the PCM calibration is now available to repair their vehicle.

Dealers should inspect and repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $7,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information – All Vehicles
Attachment IV: (Removed)
Attachment V: Vehicle Did Not Pass Fuel Tank Inspection – Fuel Tank Not Available – Customer Information Sheet
Attachment VI: (Removed)
Owner Notification Letters
Recall Reimbursement Plan

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

ATTACHMENT I

Safety Recall 15S34 – Supplement #3
Certain 2010-2011 Model Year Fusion and Milan Vehicles Equipped with 2.5L or 3.0L Engines
Fuel Tank and Canister Purge Valve Inspection and Repair

OASIS ACTIVATION

OASIS was activated on November 23, 2015.

FSA VIN LISTS ACTIVATION

FSA VIN lists were available through https://web.fsavinlists.dealerconnection.com on November 23, 2015. Owner names and addresses will be available by April 22, 2016.

NOTE: Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries.

Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.

STOCK VEHICLES

Use OASIS to identify any affected vehicles in your used vehicle inventory.

SOLD VEHICLES

Owners of all affected vehicles will be directed to dealers for repairs
Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
Correct other affected vehicles identified in OASIS which are brought to your dealership.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

If additional repairs identified are necessary to complete the FSA, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

OWNER REFUNDS

This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
Refunds will only be provided for the cost associated with CPV replacement, vapor canister replacement, or fuel tank replacement caused by cracks in the fuel tank.

SHORT TERM RENTAL VEHICLES

Dealers are pre-approved for up to 2 days for a comparable rental vehicle to accommodate intermittent delays when ordering canister purge valves or vapor canisters. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the day(s) the vehicle is at the dealership for part replacement. Prior approval for more than 2 rental days is required from the SSSC via the SSSC Web Contact Site.

For vehicles with fuel tanks that do not pass inspection, refer to the Long Term Rental section below.

LONG TERM RENTAL VEHICLES AND STORAGE (FUEL TANK INSPECTION DID NOT PASS)

For affected vehicles that do not pass the fuel tank inspection and cannot be repaired at this time due to parts shortages, dealers are to provide owners a long term rental vehicle.

Prior approval from the SSSC via the SSSC Web Contact Site is required for all rental vehicle requests.

Ford Motor Company will provide reimbursement for rental vehicle costs following Extended Service Plan (ESP) guidelines. Prior approval from the SSSC is also required for special rental needs and costs above ESP guidelines.
The customer should be offered a like Ford or Lincoln Motor Company brand vehicle.
- In the event that a Ford or Lincoln Motor Company vehicle is not available, the customer should be provided a like non-Ford vehicle within a comparable vehicle rental class. Every effort should be made to swap customers into a Ford or Lincoln vehicle as they become available.
- If a vehicle is not available in the same vehicle rental class, the customer may be offered the next higher vehicle rental class.
Traveling owners may incur additional rental fees for one-way rentals, which are also reimbursable under this FSA.
Rental vehicle days for this FSA will NOT be removed from dealer’s TAP allocation/budget.
A monthly $50.00 vehicle storage and maintenance allowance will be provided to dealers for vehicles held longer than 30 days to ensure the vehicle is returned to the owner in good, operable condition after parts are available and installed to complete this recall program.
- At least once per month, dealers are requested to perform the following maintenance items:
- Start and run the engine for approximately 15 minutes to keep the battery charged. o Maintain approximately ¼ tank of fuel during storage.
- If possible, move the vehicle to avoid tire flat spots and apply the brakes several times to minimize brake rotor corrosion.

NOTE: Any vehicles that were previously grounded due to a verified fuel tank leak should be repaired and returned to customers, and any long term rental vehicles returned. Any remaining claims for long term rental or storage and maintenance using program code 15A05 must be submitted before September 1, 2016 to be eligible for payment.

LONG TERM RENTAL TRACKING AND ALLOWANCE (If approved by the SSSC)

Dealers are authorized to claim an administrative allowance of 0.2 hours to assist customers with arranging a rental vehicle. Claiming the administrative allowance identifies vehicles that have been taken out of service.

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
- DWE: refer to ACESII manual for claims preparation and submission information.
- OWS: when entering claims in DMS software, select claim type 31: Field Service Action. The FSA number (15S34) is the sub code.
Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.
For short term rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar amounts.
- Program Code: 15S34 – Misc. Expense: Total amount
- Expense: RENTAL
Submit refunds on a separate repair line.
- Program Code: 15S34 – Expense: ADMIN
- Expense: REFUND – Misc. Expense: 0.2 Hrs.
Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim.

NOTE: Maintain supporting documentation for all Miscellaneous Expenses according to procedure as identified in the Warranty and Policy Manual.

Additional Claiming Instructions (If approved by the SSSC) – must be submitted before September 1, 2016 to be eligible for payment

Claiming administrative allowance for arranging rentals/alternate transportation:
- Claims should be submitted as soon as the customer is provided the rental vehicle. o Repair Date should be the date the customer took delivery of the rental vehicle. o Claim on the same repair line as the inspection (15S34EE or 15S34FF).
  - Program Code: 15S34 – Misc. Expense: 2 Hrs.
  - Expense: ADMIN
- Claiming for long term rental and owner alternate transportation refunds:
  - Program Code: 15A05 – Misc. Expense: Total amount
  - Expense: RENTAL
- Long term rental costs will need to be claimed on a monthly basis with separate repair orders. Dealers will need to re-contact the Special Service Support Center for a new approval code to be used on each repair order.
  - Claim on the same repair line with the rental costs on a monthly basis.
    - Program Code: 15A05 – Misc. Expense: $50.00
    - Expense: STORE
Claiming for Vehicle Storage and Maintenance:
- Storage and Maintenance can be claimed in combination with rental costs, if applicable, on a monthly basis. Dealers will need to re-contact the Special Service Support Center for a new prior approval to be used on each repair order.
- Dealers are authorized to claim a monthly $50.00 vehicle storage and maintenance fee to be used when labor operations 15S34EE or 15S34FF are claimed due to a fuel tank failing inspection and the customer requiring a rental.
- This allowance can only be claimed if labor operations 15S34EE or 15S34FF were previously claimed and the vehicle has been in storage for 30 days or more.

ATTACHMENT II

Safety Recall 15S34 – Supplement #2
Certain 2010-2011 Model Year Fusion and Milan Vehicles Equipped with 2.5L or 3.0L Engines
Fuel Tank and Canister Purge Valve Inspection and Repair

New! LABOR ALLOWANCES

Description	Drive Type	Labor Operation	Labor Time
Reprogram PCM (IDS release 99.05 or later) Test CPV – passes Inspect fuel tank	FWD	15S34B	1.0 Hours
	AWD	15S34B	0.7 Hours
Reprogram PCM (IDS release 99.05 or later) Test CPV – fails (replace CPV) Inspect and replace vapor canister if needed Inspect fuel tank	FWD	15S34C	1.3 Hours
	AWD	15S34C	1.0 Hours
Additional time to replace fuel tank if inspection fails (claim with labor operations 15S34B or 15S34C)	FWD	15S34D	1.8 Hours
	AWD	15S34D	2.2 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION

NOTE: Fuel tanks are expected to be available the week of July 4, 2016.

Part Number	Description	Order Quantity
9U5Z-9C915-H	CPV	1
9E5Z-9D653-C	Vapor canister	1
4L3Z-9276-AA	Fuel pump module seal	1
CE5Z-9002-BR	Fuel tank – 2.5L vehicles only	1
CE5Z-9002-CR	Fuel tank – 3.0L FWD vehicles only	1
AE5Z-9002-CR	Fuel tank – 3.0L AWD vehicles only	1

The DOR/COR number for this recall is 51013.

For fuel tanks, contact the SSSC via the SSSC web contact site to place orders. For all other parts, order through normal order processing channels. Fuel tank orders placed with the SSSC will be fulfilled on a first in, first out basis once fuel tanks become available.

Dealers will be notified via a DOES II communication if circumstances warrant a change in part supply strategy and when open ordering resumes.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 “WARRANTY PARTS RETENTION AND RETURN POLICIES.”

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

ATTACHMENT III

CERTAIN 2010-2011 MODEL YEAR FUSION AND MILAN VEHICLES EQUIPPED WITH 2.5L OR 3.0L ENGINES — FUEL TANK INSPECTION AND REPAIR

OVERVIEW

In some of the affected vehicles, the vapor Canister Purge Valve (CPV) may develop an internal leak which, under certain circumstances, can allow excessive vacuum to build in the fuel tank. Repeated cycles of this condition may cause a crack in the fuel tank, resulting in a fuel leak or fuel odor. A fuel leak in the presence of an ignition source can lead to a fire.

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

Repair Flow Chart

Module Reprogramming

Important Information for Module Programming

NOTE: When programming or reprogramming a module, use the following basic checks to ensure programming completes without errors.

Make sure the 12V battery is fully charged before carrying out the programming steps and connect IDS/scan tool to a power source.
Inspect Vehicle Communication Module (VCM) and cables for any damage. Make sure scan tool connections are not interrupted during programming.
A hardwired connection is strongly recommended.
Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC system, etc.) and close doors.
Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio, etc.).
Follow all scan tool on-screen instructions carefully.
Disable IDS/scan tool sleep mode, screensaver, hibernation modes.
Create all sessions Key On Engine Off (KOEO). Starting the vehicle before creating a session will cause errors within the programming inhale process.

NOTE: Reprogram appropriate vehicle modules before performing diagnostics and clear all Diagnostic Trouble Codes (DTCs) after programming. For DTCs generated after reprogramming, follow normal diagnostic service procedures.

Connect a battery charger to the 12V battery.
Reprogram the Powertain Control Module (PCM) using IDS release 99.05 or higher.

NOTE: Calibration files may also be obtained at www.motorcraftservice.com.

NOTE: Follow the IDS on-screen instructions to complete the reprogramming procedure.

Disconnect the battery charger from the 12V battery, once the reprogramming has completed.
Proceed to Canister Purge Valve (CPV) Testing on Page 4.

Canister Purge Valve Testing

With the vehicle in NEUTRAL, position it on a hoist. Please follow the Workshop Manual (WSM) procedures in Section 100-02.

NOTE: Ensure that the VACUTEC Smoke Machine or equivalent is properly calibrated for a 0.020″ leak test following the manufacturer’s instructions.

Disconnect the vapor tube-to-CPV quick connect coupling. Please follow the WSM procedures in Section 310-00. See Figure 1.

NOTE: 2.5L shown, 3.0L similar.

FIGURE 1

Using suitable adapters, connect the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester or equivalent to the port on the CPV. See Figure 2.

NOTE: 2.5L shown, 3.0L similar.

FIGURE 2

With the ignition in the “OFF” position, test the CPV for leaks by applying pressure from the tester and monitoring for air flow on the gauge. A good CPV will register a leak rate of less than 0.020″.
Is CPV leak rate less than 0.020″?
- YES – Reconnect the vapor tube-to-CPV quick connect coupling. Proceed to Fuel Tank Inspection on Page 7.
- NO – Replace the CPV following the WSM procedures in Section 303-13, then proceed to Vapor Canister Inspection on Page 6.

Vapor Canister Inspection

IMPORTANT: Liquid fuel may be present inside of the vapor canister. Ensure you are using proper precautions while servicing.

Remove the vapor canister from the vehicle. Please follow the WSM procedures in Section 303-13.
While holding the vapor canister, tip the EVAP hose ports downward to determine if there is any liquid fuel within the canister.
Is there any liquid fuel in the canister?
- YES – Install a new vapor canister following the WSM procedures in Section 303-13.
- NO – Reinstall the vapor canister following the WSM procedures in Section 303-13.
Proceed to Module Reprogramming on Page 7.

INSPECTION PROCEDURE

Fuel Tank Inspection

Inspect the fuel tank for any signs of fuel staining on the bottom of the fuel tank. See Figure 3.

NOTE: AWD Vehicles Only – Fuel tanks come equipped with a plastic shield covering the tank. See Figure 4.

a. Remove the fuel tank strap bolts and strap from the RH side of the fuel tank.

b. Remove the two push pins and bend the plastic shield downward to inspect the RH side of the fuel tank.

c. Reinstall the fuel tank strap, bolts and shield push pins. Perform the same inspection steps for the LH side of the fuel tank (Steps a-c).

d. If fuel tank replacement is not required, tighten the fuel tank strap bolts to 40 Nm (30 lb-ft).

FIGURE 3

FIGURE 4

Is there fuel staining on the bottom of the fuel tank?
- YES – Replace the fuel tank. Please follow the WSM procedures in Section 310-01. Repair is complete after fuel tank replacement has occurred.
  NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 below. Full removal of the exhaust muffler and tailpipe assembly is not required.
- NO – FWD Vehicles – Proceed to Step 3.
  AWD Vehicles – No repairs are needed at this time.

NOTE: Some fuel staining may be present on the top of the fuel tank if the fuel pump has been replaced previously. Fuel staining on the top of the fuel tank caused by prior fuel pump service is not an indication of a fuel tank leak.

FWD Vehicles Only

NOTICE: When lowering the fuel tank, do not exceed the stated distance. Lowering the fuel tank too far can cause damage to fuel lines and other components.

Partially lower the fuel tank to inspect the top of the fuel tank for any signs of fuel staining. See Figures 5 and 6.
1. Detach the exhaust isolators. Position aside and support the exhaust assembly.
2. Remove the fuel tank heat shield.
3. Use a suitable powertrain lift to support the fuel tank.
4. Remove the four fuel tank bolts and lower the fuel tank approximately 1.75 in (44.45 mm). See Figure 6 on Page 9.

NOTE: 2.5L shown, 3.0L similar.

FIGURE 5

Check the top RH side of the fuel tank for signs of cracks. See Figures 4 and 5. Is cracking present?
- YES – Replace the fuel tank. Please follow the WSM procedures in Section 310-01.
  NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 on the previous page. Full removal of the exhaust muffler and tailpipe assembly is not required.
- NO – Reassemble the vehicle. No repairs are needed at this time.

When reinstalling the fuel tank strap bolts tighten to 40 Nm (30 lb-ft).

FIGURE 6

NOTE: Fuel tank removed for clarity.

FIGURE 7

Recovering a module when programming has resulted in a blank module:
NEVER DELETE THE ORIGINAL SESSION!

Obtain the original IDS that was used when the programming error occurred during Module Reprogramming (MR) or Programmable Module Installation (PMI).
Disconnect the VCM from the Data Link Connector (DLC) and the IDS.
Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.
Locate the ORIGINAL vehicle session when programming failed. This should be the last session used in most cases. If not, use the session created on the date that the programming failed.

NOTE: If the original session is not listed in the previous session list, click the ”Recycle Bin” icon at the lower right of the previous session screen. This loads any deleted sessions and allows you to look through them. Double-click the session to restore it.

Once the session is loaded, the failed process should resume automatically.
If programming does not resume automatically, proceed to the Module Programming menu and select the previously attempted process, PMI or MR.
Follow all on-screen prompts/instructions.
The last screen on the IDS may list additional steps required to complete the programming process. Make sure all applicable steps listed on the screen are followed in order.

Safety Recall 15S34 – Did Not Pass Fuel Tank Inspection
Customer Information Sheet

Ford Motor Company is voluntarily recalling certain 2010 and 2011 model year Fusion and Milan vehicles. Your dealer completed an inspection of the fuel tank on your vehicle and identified that it did not pass the inspection criteria. As a result, your vehicle will require a fuel tank replacement and a Powertrain Control Module (PCM) software update to complete the repair.

Parts for the fuel tank replacement and the PCM software update are not currently available. We apologize for any inconvenience this may cause you, and want you to know we are working diligently

to accelerate timing. Your dealer is authorized to provide a rental vehicle for your personal transportation at no charge (except for fuel) while your vehicle is at the dealership. You will be notified of any changes or when the final repair of your vehicle has been completed. Once your vehicle is repaired and you are notified by the dealer, you will have two additional business days to return the rental vehicle without charge.

Again, we apologize for the inconvenience this situation causes and assure you that we are doing everything possible to expedite resolution.

Sincerely,

Ford Motor Company

Ford Customer Service Division

Ford Motor Company
Recall Reimbursement Plan for 15S34

Ford and Lincoln dealers are in the best position to quickly and efficiently process reimbursement requests. However, federal legislation requires all motor vehicle manufacturers to establish processes through which customers may seek recall reimbursement directly from the manufacturer or from the dealers.

Regarding the specific reimbursement plan for Recall #15S34, owners who have paid for service to remedy the defect or noncompliance must have had that service performed prior to January 31, 2016. After this date, if repairs related to this recall are performed by a non-Ford repair facility in an emergency situation, customers must submit any refund requests through their dealership. As required by this federal regulation, Ford Motor Company submitted the details of its latest General Recall Reimbursement Plan in a letter to the National Highway Traffic Safety Administration (NHTSA) in February 2015. The following is the text of that letter and the Plan:

General Recall Reimbursement Plan
(As submitted to the NHTSA)

Pursuant to the requirements set forth in 49 CFR Part 573 and Part 577 of the Code of Federal Regulations, Ford Motor Company (Ford) is submitting required information pertaining to our general reimbursement plan for the cost of remedies paid for by vehicle owners before they are notified of a related safety recall.

Set forth below is Ford’s general plan to reimburse owners and purchasers for costs incurred for remedies in advance of notification of potential safely-related defects or noncompliances pursuant to Part 573.6 (c)(8)(i). This plan has not changed since our February 20, 2015 submission.

Reimbursement Notification

Ford’s notice to a vehicle owner in accordance with 49 CFR Part 577 will indicate that Ford is offering a refund if the owner paid to have service to remedy the defect or noncompliance prior to a specified ending date. In accordance with Part 573.13 (c)(2), this ending date will be defined as a minimum of ten calendar days after the date on which Ford mailed the last of its Part 577 notifications to owners, and will be indicated in the specific reimbursement plan available to owners for an individual recall. This notice will direct owners to seek eligible reimbursement through authorized dealers or, at their option, directly through Ford at the following address:

Ford Motor Company
P.O. Box 6251
Dearborn, MI 48121-6251

Ford notes that this rule allows for the identification of a beginning date for reimbursement eligibility. Under the rule, an owner who paid to remedy the defect or noncompliance prior to the identified beginning date would not be eligible for reimbursement. Ford generally has not established such a beginning date for reimbursement eligibility and does not presently anticipate changing this general policy. However, in any case where Ford determines a beginning date is appropriate, Ford will indicate that date in the owner notice. As permitted by 577.11(e), Ford may not include a reimbursement notification when all vehicles are well within the warranty period, subject to approval by the agency.

Costs to be Reimbursed

For vehicles, reimbursement will not be less than the lesser of:

The amount paid by the owner for the remedy that specifically addressed and was reasonably necessary to correct the defect or noncompliance that is the subject of the recall, or
The cost of parts for the remedy (to be no more than the manufacturer’s list retail price for authorized part(s), plus associated labor at local labor rates, miscellaneous fees (such as disposal of waste) and taxes.

For replacement equipment, reimbursement will be the amount paid by the owner for the replacement item (limited by the amount of the retail list price of the defective or noncompliant item that was replaced, plus taxes, where the brand or model purchased by the owner was different than the brand or model that was the subject of the recall). If the item of motor vehicle equipment was repaired, the reimbursement provisions identified above for vehicles will apply.

Ford notes that costs incurred by the owner within the period during which Ford’s original or extended warranty would have provided for a free repair of the problem will not be eligible for reimbursement, as provided by Part 573.13 (d)(1).

Entities Authorized to Provide Reimbursement

Ford will continue to use authorized dealers to reimburse owners under the specific reimbursement plans for a particular recall, and will encourage owners to pursue requests for reimbursement directly through dealers to expedite reimbursement. Ford will also provide a mailing address to which customers can, at their option, send requests for reimbursement directly to Ford, as previously noted. Requests for reimbursement sent directly to Ford may take up to 60 days to process. Whether the owner chooses to pursue reimbursement requests through a dealer or directly through Ford, the owner will be directed to submit the required documentation, upon which reimbursement eligibility will be determined.

Required Documentation

The reimbursement determination will depend upon the information provided by the customer. Consistent with Part 573.13 (d)(4) the following information must be submitted:

Claimant name and address
Vehicle make, model, and model year
Vehicle identification number (VIN) and, for replacement equipment, a description of such equipment or, for tires, the model, size and TIN (DOT code)
Identification of the recall number (either the Ford recall number or the NHTSA recall number)
Identification of the owner of the recalled vehicle at the time that the pre-notification remedy was obtained
An original receipt for the pre-notification remedy that includes a breakdown of the amount for parts, labor, other costs and taxes, including costs for the replacement item. Where the receipt covers work other than to address the recall or noncompliance, Ford may require the claimant to separately identify costs that are eligible for reimbursement.
If the remedy was obtained during the warranty period, documentation indicating that the warranty was not honored or the warranty repair did not correct the problem related to the recall.

Failure to submit all of the above information may result in denial of the reimbursement request.

Additional Information

The Part 577 required owner notice will provide a toll-free telephone number through which specific information about the reimbursement plan can be requested from Ford. This general reimbursement plan will be incorporated into notifications pursuant to Part 573.6 by reference. Information specific to an individual recall also may be incorporated into the Part 573.6 notification.

January 2016

* * * IMPORTANT SAFETY RECALL * * *
(PROGRAMA DE SEGURIDAD IMPORTANTE)

Safety Recall Notice 15S34 / NHTSA Recall 15V793
Aviso de Revisión de Seguridad 15S34

Mr. John Sample
123 Main Street
Anywhere, USA 12345

Your Vehicle Identification Number (VIN): 12345678901234567

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above.

We apologize for this situation and want to assure you that, with your assistance, we will correct this condition. Our commitment, together with your dealer, is to provide you with the highest level of service and support.

What is the issue?	On your vehicle, pressure cycles within the fuel system may cause the surface of the fuel tank to develop a crack, which may result in a fuel odor or leak. A fuel leak in the presence of an ignition source can lead to a fire. A cracked fuel tank may also exceed the maximum allowable hydrocarbon evaporative emissions.
What will Ford and your dealer do?	Ford Motor Company has authorized your dealer to update your vehicle’s Powertrain Control Module (PCM) with a calibration that will help prevent pressure cycles in the fuel tank that may be caused by a leaking Canister Purge Valve (CPV). The PCM calibration will be available on February 4, 2016. Additionally, your dealer will test or inspect your vehicle’s CPV, vapor canister, and fuel tank, and replace any parts that do not pass. This repair will be completed free of charge (parts and labor). If your vehicle’s fuel tank needs to be replaced, you should know that replacement fuel tanks are anticipated to become available in the third quarter of 2016. We apologize for any inconvenience this delay may cause you, and want you to know we are working diligently to accelerate part availability.
How long will it take?	The time needed for this repair is less than one-half day. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.
What should you do?	Please contact your dealer and request a service appointment for February 4, 2016 or later to have your vehicle’s PCM calibration updated and receive diagnosis and repair relating to Safety Recall 15S34. Provide the dealer with the VIN of your vehicle, which is printed near your name at the beginning of this letter. If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Do you need a rental vehicle?	If your dealer determines that your vehicle’s fuel tank is leaking, your dealer is authorized to provide a rental vehicle for your personal transportation at no charge (except for fuel and insurance) while your vehicle is at the dealership for repairs. Please see your dealer for guidelines and limitations.
Have you previously paid for this repair?	If you have previously paid for a repair that addresses the issue described in this letter, you still need to have this recall performed to ensure the correct parts and procedures were used. You may be eligible for a refund of previously paid repairs. Refunds will only be provided for service related to fuel tank replacement due to fuel leak, CPV replacement, and vapor canister replacement due to liquid fuel contamination. To verify eligibility and expedite reimbursement, give your paid original receipt to your dealer. Refund requests may also be sent directly to Ford Motor Company. To request your refund from Ford, send the refund request with all required documentation, including your original repair receipt (no photocopies), to Ford Motor Company at P.O. Box 6251, Dearborn, Michigan 48121-6251. Refund requests mailed to this address may take up to 60 days to process. Your original receipt will be returned to you. Detailed information regarding eligibility for Ford’s reimbursement program and documentation requirements may be obtained by contacting the Ford Customer Relationship Center at 1-866-436-7332.
What if you no longer own this vehicle?	If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. You received this notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner.
California and Massachusetts Registration Requirements	The State of California and the Commonwealth of Massachusetts require the completion of emission-related recall repairs prior to vehicle registration renewal. If your vehicle is registered in California or Massachusetts, it is subject to these requirements. When your dealer completes this emission-related recall repair, you will receive a Vehicle Emission Recall Proof of Correction certificate. Please make sure that you receive a certificate from your dealer and that you have it with you when you renew your vehicle registration. It is also important for you to know that the certificate should be returned to the Department of Motor Vehicles (DMV) only if it is requested by the DMV. Otherwise, this certificate is to be held by you for your records. In order to ensure your full protection under emissions warranty provisions, and to avoid any inconvenience when renewing your registration, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle.
Can we assist you further?	If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance. RETAIL OWNERS: If you still have concerns, please contact the Ford Motor Company Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you. For the hearing impaired call 1800-232-5952 (TDD). Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). If you wish to contact us through the Internet, our address is: www.Fordowner.com. Para asistencia en Español: Si necesita ayuda o tiene alguna pregunta, por favor llame al Centro de Relación con Clientes al 1-866-436-7332 y presione 2 para Español. FLEET OWNERS: If you still have concerns, please contact the Fleet Customer Information Center at 1-800-34-FLEET, Option #3 and one of our representatives will be happy to assist you. Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). Or you may contact us through the Internet at www.fleet.ford.com. If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590 or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1800-424-9153) or go to www.safercar.gov. Reference NHTSA Safety Recall 15V793.

Thank you for your attention to this important matter.

Ford Customer Service Division

January 2016

* * * IMPORTANT SAFETY RECALL * * *
(PROGRAMA DE SEGURIDAD IMPORTANTE)

Safety Recall Notice 15S34 / NHTSA Recall 15V793
Aviso de Revisión de Seguridad 15S34

Mr. John Sample
123 Main Street
Anywhere, USA 12345

Your Vehicle Identification Number (VIN): 12345678901234567

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Ford Motor Company has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above.

What is the issue?	On your vehicle, pressure cycles within the fuel system may cause the surface of the fuel tank to develop a crack, which may result in a fuel odor or leak. A fuel leak in the presence of an ignition source can lead to a fire. A cracked fuel tank may also exceed the maximum allowable hydrocarbon evaporative emissions.
What will Ford and your dealer do?	Ford Motor Company is in the process of developing the parts for this repair. When the repair is available for Safety Recall 15S34, you will be notified by Ford Motor Company via mail to schedule a service appointment with your dealer to update the calibration in your vehicle’s Powertrain Control Module (PCM), test or inspect your vehicle’s Canister Purge Valve (CPV), vapor canister, and fuel tank, and replace any parts that do not pass. The PCM calibration update is anticipated to become available in the first quarter of 2016, and replacement fuel tanks are anticipated to become available in the third quarter of 2016. We apologize for any inconvenience these delays may cause you. We are working diligently to accelerate part availability. This repair will be completed free of charge (parts and labor).
How long will it take?	The time needed for this repair is less than one-half day. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.
What should you do? Malfunction Indicator Light	When the repair is available for Safety Recall 15S34, you will be notified by Ford Motor Company via mail to schedule a service appointment with your dealer. Until the repair becomes available, if your vehicle exhibits symptoms of a fuel odor, fuel on the ground, or illumination of the Malfunction Indicator Light (MIL), please contact your dealer immediately and request a service appointment for diagnosis and repair relating to Safety Recall 15S34. Provide the dealer with the VIN of your vehicle, which is printed near your name at the beginning of this letter. If your vehicle does not exhibit these symptoms, no action is needed until you receive a follow up notification to schedule a service appointment. If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions. Until the repair becomes available, if you have any questions regarding this recall, feel free to contact Ford directly by calling 1-866-436-7332. Representatives are available to answer your questions. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Do you need a rental vehicle?	If your dealer determines that your vehicle’s fuel tank is leaking, your dealer is authorized to provide a rental vehicle for your personal transportation at no charge (except for fuel and insurance) while your vehicle is at the dealership for repairs. Please see your dealer for guidelines and limitations.
Have you previously paid for this repair?	If you have previously paid for a repair that addresses the issue described in this letter, you still need to have this recall performed to ensure the correct parts and procedures were used. You may be eligible for a refund of previously paid repairs. Refunds will only be provided for service related to fuel tank replacement due to fuel leak, CPV replacement, and vapor canister replacement due to liquid fuel contamination. To verify eligibility and expedite reimbursement, give your paid original receipt to your dealer. Refund requests may also be sent directly to Ford Motor Company. To request your refund from Ford, send the refund request with all required documentation, including your original repair receipt (no photocopies), to Ford Motor Company at P.O. Box 6251, Dearborn, Michigan 48121-6251. Refund requests mailed to this address may take up to 60 days to process. Your original receipt will be returned to you. Detailed information regarding eligibility for Ford’s reimbursement program and documentation requirements may be obtained by contacting the Ford Customer Relationship Center at 1-866-436-7332.
What if you no longer own this vehicle?	If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. You received this notice because government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which indicate that you are the current owner.
California and Massachusetts Registration Requirements	The State of California and the Commonwealth of Massachusetts require the completion of emission-related recall repairs prior to vehicle registration renewal. If your vehicle is registered in California or Massachusetts, it is subject to these requirements. When your dealer completes this emission-related recall repair, you will receive a Vehicle Emission Recall Proof of Correction certificate. Please make sure that you receive a certificate from your dealer and that you have it with you when you renew your vehicle registration. It is also important for you to know that the certificate should be returned to the Department of Motor Vehicles (DMV) only if it is requested by the DMV. Otherwise, this certificate is to be held by you for your records. In order to ensure your full protection under emissions warranty provisions, and to avoid any inconvenience when renewing your registration, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle.
Can we assist you further?	If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance. RETAIL OWNERS: If you still have concerns, please contact the Ford Motor Company Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you. For the hearing impaired call 1-800-232-5952 (TDD). Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). If you wish to contact us through the Internet, our address is: www.Fordowner.com. Para asistencia en Español: Si necesita ayuda o tiene alguna pregunta, por favor llame al Centro de Relación con Clientes al 1-866-436-7332 y presione 2 para Español. FLEET OWNERS: If you still have concerns, please contact the Fleet Customer Information Center at 1-800-34-FLEET, Option #3 and one of our representatives will be happy to assist you. Representatives are available Monday through Friday: 8:00AM – 8:00PM (Eastern Time). Or you may contact us through the Internet at www.fleet.ford.com. If you are still having difficulty getting your vehicle repaired in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. S.E., Washington, D.C. 20590 or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1800-424-9153) or go to www.safercar.gov. Reference NHTSA Safety Recall nhtsa.dot.gov/owners/SearchResults?searchType=ID&targetCategory=R&searchCriteria.nhtsa_ids=15V793" target="_blank" rel="noopener">15V793.

Thank you for your attention to this important matter.

Ford Customer Service Division

Service Information & Reprogramming

Software necessary to program electronic modules to the latest calibration level, perform module initialization (PATS), and set Programmable Parameters on Ford, Lincoln and Mercury vehicles.

Ford Module Programming (FMP) is a software application that allows subscribers to program electronic modules on Ford, Lincoln and Mercury vehicles. It can be used for:

Reprogramming emission-related (OBDII) modules on some vehicles manufactured in 1995 and all vehicles manufactured from 1996 to the present
Reprogramming or reconfiguring non-emission-related modules on many vehicles (UBP and MS-CAN not supported)

In addition, module initialization (PATS) functions such as Keycode Erase/Reprogram and PCM Parameter Reset can be done using this application.

J2534 Device using Ford Module Programming (FMP) can Reprogram and Configure most Modules.

Latest Calibration Information

Module Build Data (As-Built)
Use VIN to obtain As-Built data

www.motorcraftservice.com